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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1620 (Engine Cooling System) >> Repair Instructions >> Thermostat Housing Crossover Replacement (6.6L Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the thermostats with the seals.

    The thermostat with the vent valves goes toward the rear of the engine. Install with the vent valves towards the rear of the engine.

  2. Install the thermostat cover and gasket.
    NOTE: Refer to FASTENER NOTICE .
  3. Install the thermostat cover bolts.

    Tighten 

    Tighten the bolts to 21 N.m (15 lb ft).

    Fig 1: Install Thermostat, Seals, Cover & Bolts
    G02109155Courtesy of GENERAL MOTORS CORP.
  4. Install a new O-ring to the bypass pipe. Lubricate the O-ring with coolant.
  5. Install the bypass pipe to the thermostat housing crossover.
    Fig 2: Install O-Ring & Bypass Pipe
    G02109156Courtesy of GENERAL MOTORS CORP.
  6. Install NEW thermostat housing gaskets.
  7. Install a NEW O-ring for the bypass pipe to the water pump.
  8. Install the thermostat housing with the bypass pipe.
  9. Install the bypass pipe to water pump bolts.

    Tighten 

    Tighten the bolts to 21 N.m (15 lb ft).

  10. Install the thermostat housing bolts and nuts.

    Tighten 

    Tighten the bolts and nuts to 21 N.m (15 lb ft).

  11. Install the fuel line bracket and bolt.

    Tighten 

    Tighten the bolt to 21 N.m (15 lb ft).

    Fig 3: Install Thermostat Housing Bolts & Nuts
    G02109157Courtesy of GENERAL MOTORS CORP.
  12. Install the turbocharger coolant return pipe hose and clamps.
  13. Install the cooling fan pulley. Refer to Cooling Fan Pulley Replacement (6.6L Engine) .
    Fig 4: Install Turbocharger Coolant Return Pipe Hose & Clamps
    G02109158Courtesy of GENERAL MOTORS CORP.
  14. Install a NEW O-ring seal to the heater inlet pipe.
  15. Install the heater inlet pipe to the thermostat housing crossover.
  16. Install the heater inlet pipe to thermostat housing crossover bolt.

    Tighten 

    Tighten the bolt to 21 N.m (15 lb ft).

  17. Install the heater inlet pipe to fuel filter bolt.

    Tighten 

    Tighten the bolt to 21 N.m (15 lb ft).

    Fig 5: Install O-Ring & Heater Inlet Pipe
    G02109159Courtesy of GENERAL MOTORS CORP.
  18. Install the generator bracket and bolts.

    Tighten 

    Tighten the bolts to 50 N.m (37 lb ft).

  19. Install the ribbed idler pulley and the bolt.

    Tighten 

    Tighten the bolt to 43 N.m (32 lb ft).

  20. Install the heater outlet hose bracket bolt.

    Tighten 

    Tighten the bolt to 21 N.m (15 lb ft).

    Fig 6: Install Ribbed Idler Pulley & Bolt
    G02109160Courtesy of GENERAL MOTORS CORP.
  21. Install the fuel bleed valve and PCV oil separator bracket nuts to the generator bracket.

    Tighten 

    Tighten the nuts to 25 N.m (18 lb ft).

    Fig 7: Install Fuel Bleed Valve & PCV Oil Separator Bracket Nuts
    G02109161Courtesy of GENERAL MOTORS CORP.
  22. Install the power steering pump bracket and bolts.

    Tighten 

    Tighten the bolts to 46 N.m (34 lb ft).

  23. Install the water outlet. Refer to Water Outlet Tube Replacement (6.6L Engine) .
    Fig 8: Install Power Steering Pump Bracket & Bolts
    G02109162Courtesy of GENERAL MOTORS CORP.
  24. Position the generator positive cable.
  25. Install the generator positive cable in the clip on the engine front cover.
  26. Install the generator positive cable nut.

    Tighten 

    Tighten the nut to 9 N.m (80 lb in).

  27. Install the battery positive cable junction block bracket and bolt to the power steering pump.

    Tighten 

    Tighten the bolt to 9 N.m (80 lb in).

    Fig 9: Install Generator Positive Cable Nut
    G02109163Courtesy of GENERAL MOTORS CORP.
  28. Connect the ECT sensor electrical connector.
  29. Connect the generator electrical connector (1).
    Fig 10: Connect ECT Sensor Electrical Connector
    G02109164Courtesy of GENERAL MOTORS CORP.
  30. Position the A/C compressor.
  31. Install the A/C compressor bolts.

    Tighten 

    Tighten the bolts to 50 N.m (37 lb ft).

    Fig 11: Install A/C Compressor & Bolts
    G02109165Courtesy of GENERAL MOTORS CORP.
  32. Connect the A/C cut out switch electrical connector.
  33. Connect the A/C compressor clutch electrical connector (5).
  34. Install the drive belt. Refer to DRIVE BELT ROUTING .
  35. Install the upper fan shroud. Refer to Fan Shroud Replacement - Upper (W/O M74)  or  Fan Shroud Replacement - Upper (W/M74)   .
  36. Fill the cooling system. Refer to Draining and Filling Cooling System .
  37. Connect the negative battery cables. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (SINGLE BATTERY) or  BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (AUXILIARY BATTERY)  .
    Fig 12: Connect A/C Compressor Clutch Electrical Connector
    G02109166Courtesy of GENERAL MOTORS CORP.
  38. Install the upper intake manifold cover.
  39. Install the upper intake manifold cover to the outlet duct.
  40. Tighten the outlet duct clamp at the upper intake manifold cover.

    Tighten 

    Tighten the clamp to 6 N.m (53 lb in).

    Fig 13: Install Upper Intake Manifold Cover
    G02109167Courtesy of GENERAL MOTORS CORP.
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